U.S. patent number 10,056,625 [Application Number 14/918,481] was granted by the patent office on 2018-08-21 for fluid manifold attached by interface to fuel storage for fuel cell system.
This patent grant is currently assigned to INTELLIGENT ENERGY LIMITED. The grantee listed for this patent is Intelligent Energy Limited. Invention is credited to Isabelle Depatie, Jeremy Schrooten, Paul Sobejko, Joerg Zimmermann.
United States Patent |
10,056,625 |
Schrooten , et al. |
August 21, 2018 |
Fluid manifold attached by interface to fuel storage for fuel cell
system
Abstract
An electrochemical cell system includes a fluid manifold having
a layered structure. The fluid manifold includes at least one
conduit layer having a first side and a second side. The at least
one conduit later has at least one conduit channel.
Inventors: |
Schrooten; Jeremy (Mission,
CA), Sobejko; Paul (North Vancouver, CA),
Zimmermann; Joerg (Vancouver, CA), Depatie;
Isabelle (Grenoble, FR) |
Applicant: |
Name |
City |
State |
Country |
Type |
Intelligent Energy Limited |
Loughborough, Leicestershire |
N/A |
GB |
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Assignee: |
INTELLIGENT ENERGY LIMITED
(Loughborough, GB)
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Family
ID: |
39765335 |
Appl.
No.: |
14/918,481 |
Filed: |
October 20, 2015 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20160043416 A1 |
Feb 11, 2016 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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13361808 |
Jan 30, 2012 |
9214687 |
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12053366 |
Mar 21, 2008 |
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60919472 |
Mar 21, 2007 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01M
8/0258 (20130101); H01M 8/2485 (20130101); H01M
8/04201 (20130101); H01M 8/2483 (20160201); H01M
8/026 (20130101); H01M 8/0271 (20130101); Y10T
137/2224 (20150401); Y02E 60/50 (20130101); Y02B
90/10 (20130101); H01M 2250/30 (20130101); Y10T
137/0352 (20150401) |
Current International
Class: |
H01M
8/02 (20160101); H01M 8/0271 (20160101); H01M
8/2485 (20160101); H01M 8/0258 (20160101); H01M
8/2483 (20160101); H01M 8/026 (20160101); H01M
8/04082 (20160101); H01M 8/24 (20160101); H01M
8/04 (20160101) |
Field of
Search: |
;429/508 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1498971 |
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Jan 2005 |
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EP |
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2004-031199 |
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Jan 2004 |
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JP |
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2006-269355 |
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Oct 2006 |
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JP |
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155569 |
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Oct 2012 |
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SG |
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WO 1995/008716 |
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Mar 1995 |
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WO |
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WO 2001/078893 |
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Oct 2001 |
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WO |
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WO 2004/034485 |
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Apr 2004 |
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WO |
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WO 2007/117212 |
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Oct 2007 |
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WO |
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WO 2008/026713 |
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Mar 2008 |
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WO |
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WO 2008/026714 |
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Mar 2008 |
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WO |
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WO 2008/113182 |
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Sep 2008 |
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WO |
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Other References
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Primary Examiner: Cullen; Sean P
Attorney, Agent or Firm: Baker & Hostetler LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. patent
application Ser. No. 13/361,808, filed Jan. 30, 2012, now granted
as U.S. Pat. No. 9,214,687, which is a continuation application of
U.S. patent application Ser. No. 12/053,366, filed Mar. 21, 2008,
now abandoned, which application claims the benefit of priority
under 35 U.S.C. .sctn. 119(e) to U.S. Provisional Patent
Application Ser. No. 60/919,472, filed Mar. 21, 2007, which
applications are herein incorporated by reference in their
entirety.
Claims
The invention claimed is:
1. A fluid manifold for feeding hydrogen from a fuel storage to a
plurality of anodes on a first side of a planar fuel cell, the
fluid manifold being substantially flat and comprising: a first
barrier layer providing at least one inlet port in fluid
communication with the fuel storage, wherein a portion of the first
barrier layer proximate to the at least one inlet port is attached
as a substantially planar interface to the fuel storage; a second
barrier layer containing at least one outlet port capable of
providing fluid communication with the plurality of anodes and
configured to provide a gas-tight seal with the first side of the
fuel cell; a first conduit layer interposed between the first
barrier layer and the second barrier layer, the first conduit layer
comprising one or more conduits to fluidicly communicate with the
at least one inlet port and the at least one outlet port; and
optionally at least one additional conduit layer comprising one or
more conduits and a corresponding additional barrier layer
comprising through-hole ports, the at least one additional conduit
and corresponding barrier layers being interposed between the first
and second barrier layers, such that the fluid manifold is a
stacked array of alternating barrier layers and conduit layers
configured to provide fluidic communication between the fuel
storage and the plurality of anodes on the first side of the fuel
cell.
2. A planar fuel cell comprising: (a) a fuel cell layer having a
first and a second side and the fuel cell layer having a plurality
of anodes, a plurality of cathodes, and an ion-conducting
electrolyte; wherein the plurality of anodes is arranged adjacently
on the first side of the fuel cell layer and the plurality of
cathodes arranged on the second side of the fuel cell layer; and
the ion-conducting electrolyte is interposed between the plurality
of anodes and the plurality of cathodes (b) a fluid manifold
fluidly coupled with the plurality of anodes on the first side of
the fuel cell layer, wherein the fluid manifold is substantially
flat and comprises: a first barrier layer providing at least one
inlet port in fluid communication with a fuel storage, wherein a
portion of the first barrier layer proximate to the at least one
inlet port is attached as a substantially planar interface to the
fuel storage; a second barrier layer containing at least one outlet
port in fluid communication with the plurality of anodes of the
fuel cell layer and configured to provide a gas-tight seal with the
first side of the fuel cell; and a first conduit layer interposed
between the first barrier layer and the second barrier layer, the
first conduit layer comprising one or more conduits configured to
fluidicly communicate with the at least one inlet port and the at
least one outlet port.
3. The planar fuel cell of claim 2, wherein the fluid manifold has
a bend radius of no less than about twice a thickness of a single
one of the first or second barrier layers or the conduit layer.
4. The planar fuel cell of claim 2 wherein one or more of the
conduits, the inlet port, and the outlet port have a hydraulic
diameter of between about 0.05 mm and about 2 mm.
5. The planar fuel cell of claim 2 wherein one or more of the
conduits, the inlet port, and the outlet port have a hydraulic
diameter of between about 0.05 mm and about 2 mm.
6. The planar fuel cell of claim 5, wherein the one or more
conduits have a surface roughness that is 1/50th of the hydraulic
diameter of the conduit.
7. The planar fuel cell of claim 2 wherein the fluid manifold
further comprises at least one additional conduit layer comprising
one or more conduits and a corresponding additional barrier layer
comprising through-hole ports, the at least one additional conduit
and corresponding barrier layers being interposed between the first
and second barrier layers, such that the fluid manifold is a
stacked array of alternating barrier layers and conduit layers
configured to provide fluidic communication between the fuel
storage and the plurality of anodes on the first side of the fuel
cell layer.
8. The planar fuel cell of claim 7 wherein one or more of the
conduits, inlet port, outlet port, and through-hole ports have a
hydraulic diameter of between about 0.05 mm and about 2 mm.
Description
TECHNICAL FIELD
The present document relates to fluid management technology. More
specifically, it relates to a fluid manifold.
BACKGROUND
Trends in technology are progressing towards smaller scales for
systems in a variety of applications. Fluidic systems can be
integrated within restrictive form factors imposed by the system to
manipulate the transport of fluid. For example, flow modulating
components can be arranged for functions such as reactant delivery,
heat transfer, and dosing of fluids.
Electronic components, such as personal electronic devices, are
trending to become smaller in size. As electronic components are
designed in smaller in size and incorporate sophisticated and
complex technology, the demands on the power supply become greater.
For instance, the power supply may need to occupy less volume or a
smaller footprint to accommodate the addition of the technology to
the device. The additional technology may also require that the
power supply last for longer periods of time. In addition, portable
electronic device may need to have energy storage maintained while
the power supply shrinks.
An example of a power supply for the electronic components is a
electrochemical cell system. In order to make a smaller
electrochemical cell system, many individual components of the
system, such as a fluid delivery component can be made smaller, but
need to meet the technical requirements of the electrochemical cell
system. For instance, the fluid delivery component may need to
maintain a certain pressure, without occupying an overall
significant volume of the electrochemical cell system, and without
interfering with the assembly of the electrochemical cell system.
Furthermore, the functionality of the electrochemical cell system
must not be compromised.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates an exploded view of a electrochemical cell
system as constructed in accordance with at least one
embodiment.
FIG. 1B illustrates a block diagram of a electrochemical cell
system in accordance with at least one embodiment.
FIG. 2 illustrates an exploded perspective view of a fluid manifold
as constructed in accordance with at least one embodiment.
FIG. 3A illustrates a cross-sectional view of a conduit layer as
constructed in accordance with at least one embodiment.
FIG. 3B illustrates a cross-sectional view of a conduit layer as
constructed in accordance with at least one embodiment.
FIG. 3C illustrates a cross-sectional view of a conduit layer as
constructed in accordance with at least one embodiment.
FIG. 4 illustrates an exploded perspective view of a fluid manifold
as constructed in accordance with at least one embodiment.
FIG. 5 illustrates an exploded perspective view of a fluid manifold
as constructed in accordance with at least one embodiment.
FIG. 6 illustrates a view of an enclosure with an interface as
constructed in accordance with at least one embodiment.
FIG. 7 illustrates a side view of an enclosure with an interface as
constructed in accordance with at least one embodiment.
FIG. 8 illustrates an exploded view of an electrochemical cell
system, as constructed in accordance with at least one
embodiment.
DETAILED DESCRIPTION
The following detailed description includes references to the
accompanying drawings, which form a part of the detailed
description. The drawings show, by way of illustration, specific
embodiments in which the fluid manifold and fuel cell fuel systems
and methods may be practiced. These embodiments, which are also
referred to herein as "examples" or "options," are described in
enough detail to enable those skilled in the art to practice the
present invention. The embodiments may be combined, other
embodiments may be utilized or structural or logical changes may be
made without departing from the scope of the invention. The
following detailed description is, therefore, not to be taken in a
limiting sense and the scope of the invention is defined by the
appended claims and their legal equivalents.
In this document, the terms "a" or "an" are used to include one or
more than one, and the term "or" is used to refer to a nonexclusive
"or" unless otherwise indicated. In addition, it is to be
understood that the phraseology or terminology employed herein, and
not otherwise defined, is for the purpose of description only and
not of limitation.
A fluid manifold is provided herein. In the following examples, a
fuel manifold for a electrochemical cell system is discussed.
However, the fluid manifold is not necessarily so limited and can
be used in other types of fluidic control systems or other types of
systems in need of fluid management. For instance, the fluid
manifold can be used to deliver or remove other types of fluids,
including, but not limited to water, oxidant, or a heat transfer
fluid. For instance, the fluid manifold includes, but is not
limited to, a fuel manifold, a heat transfer manifold, an oxidant
manifold, or a water removal manifold.
Definitions
As used herein, "fluid" refers to a continuous, amorphous substance
whose molecules move freely past one another and that has the
tendency to assume the shape of its container. A fluid may be a
gas, liquefied gas, liquid or liquid under pressure. Examples of
fluids may include fluid reactants, fuels, oxidants, and heat
transfer fluids. Fluid fuels used in fuel cells may include
hydrogen gas or liquid and hydrogen carriers in any suitable fluid
form. Examples of fluids include air, oxygen, water, hydrogen,
alcohols such as methanol and ethanol, ammonia and ammonia
derivatives such as amines and hydrazine, silanes such as disilane,
trisilane, disilabutane, complex metal hydride compounds such as
aluminum borohydride, boranes such as diborane, hydrocarbons such
as cyclohexane, carbazoles such as dodecahydro-n-ethyl carbazole,
and other saturated cyclic, polycyclic hydrocarbons, saturated
amino boranes such as cyclotriborazane, butane, borohydride
compounds such as sodium and potassium borohydrides, and formic
acid.
As used herein, "fluid enclosure" may refer to a device for storing
a fluid. The fluid enclosure may store a fluid physically or
chemically. For example, the fluid enclosure may chemically store a
fluid in active material particles.
As used herein, "active material particles" refer to material
particles capable of storing hydrogen or other fluids or to
material particles that may occlude and desorb hydrogen or another
fluid. Active material particles may include fluid-storing
materials that occlude fluid, such as hydrogen, by chemisorption,
physisorption or a combination thereof. Some hydrogen-storing
materials desorb hydrogen in response to stimuli, such as change in
temperature, change in heat or a change in pressure. Examples of
hydrogen-storing materials that release hydrogen in response to
stimuli, include metal hydrides, chemical hydrides, suitable
micro-ceramics, nano-ceramics, boron nitride nanotubes, metal
organic frameworks, palladium-containing materials, zeolites,
silicas, aluminas, graphite, and carbon-based reversible
fluid-storing materials such as suitable carbon nanotubes, carbon
fibers, carbon aerogels, and activated carbon, nano-structured
carbons or any combination thereof. The particles may also include
a metal, a metal alloy, a metal compound capable of forming a metal
hydride when in contact with hydrogen, alloys thereof or
combinations thereof. The active material particles may include
magnesium, lithium, aluminum, calcium, boron, carbon, silicon,
transition metals, lanthanides, intermetallic compounds, solid
solutions thereof, or combinations thereof.
As used herein, "metal hydrides" may include a metal, metal alloy
or metal compound capable of forming a metal hydride when in
contact with hydrogen. Metal hydride compounds can be generally
represented as follows: AB, AB2, A2B, AB5 and BCC, respectively.
When bound with hydrogen, these compounds form metal hydride
complexes.
As used herein, "occlude" or "occluding" or "occlusion" refers to
absorbing or adsorbing and retaining a substance, such as a fluid.
Hydrogen may be a fluid occluded, for example. The fluid may be
occluded chemically or physically, such as by chemisorption or
physisorption, for example.
As used herein, "desorb" or "desorbing" or "desorption" refers to
the removal of an absorbed or adsorbed substance. Hydrogen may be
removed from active material particles, for example. The hydrogen
or other fluid may be bound physically or chemically, for example.
As used herein, "contacting" refers to physically, chemically,
electrically touching or within sufficiently close proximity. A
fluid may contact an enclosure, in which the fluid is physically
forced inside the enclosure, for example.
As used herein, "composite fluid storage material" refers to active
material particles mixed with a binder, wherein the binder
immobilizes the active material particles sufficient to maintain
relative spatial relationships between the active material
particles. Examples of composite fluid storage materials are found
in commonly-owned U.S. patent application Ser. No. 11/379,970,
filed Apr. 24, 2006, which issued as U.S. Pat. No. 7,708,815 and
whose disclosure is incorporated by reference herein in their
entirety. An example of a composite fluid storage material is a
composite hydrogen storage material.
As used herein, "electrochemical layer" refers to a sheet including
one or more active functional members of an electrochemical cell.
For example, an electrochemical layer may include a fuel cell
layer. As used herein, "active functional members" refers to
components of an electrochemical cell that function to convert
chemical energy to electrical energy or convert electrical energy
to chemical energy. Active functional members exhibit
ion-conductivity, electrical conductivity, or both.
As used herein, "electrochemical cell" refers to a device that
converts chemical energy to electrical energy or converts
electrical energy to chemical energy. Examples of electrochemical
cells may include galvanic cells, electrolytic cells,
electrolyzers, fuel cells, batteries and metal-air cells, such as
zinc air fuel cells or batteries. Any suitable type of
electrochemical cell including fuel cells and appropriate materials
can be used according to the present invention including without
limitation proton exchange membrane fuel cells (PEMFCs), solid
oxide fuel cells (SOFCs), molten carbonate fuel cell (MCFCs),
alkaline fuel cells, other suitable fuel cells, and materials
thereof. Further examples of fuel cells include proton exchange
membrane fuel cells, direct methanol fuel cells, alkaline fuel
cells, phosphoric acid fuel cells, molten carbonate fuel cells or
solid oxide fuel cells.
An electrochemical cell layer, such as a fuel cell layer, may
include one or more anodes, cathodes, and electrolyte interposed
between the anodes and cathodes. In a fuel cell system, the
cathodes may be supplied with air containing oxygen for use as an
oxidizing agent, and the anodes may be supplied with hydrogen, for
example, for use as fuel. The oxidizing agent may be supplied from
air surrounding the fuel cell system, while the fuel or other
reactant fluid may be supplied from the fluid reservoir.
Arrays of unit cells can be constructed to provide varied-power
generating electrochemical cell layers in which the entire
electrochemical structure is contained within the layer. This means
additional components such as plates for collecting etc. can be
eliminated, or replaced with structures serving different
functions. Structures like those described herein are well adapted
to be manufactured by continuous processes.
Such structures can be designed in a way which does not require the
mechanical assembly of individual parts. In some embodiments, the
conductive path lengths within this structure may be kept extremely
short so that ohmic losses in the catalyst layer are minimized.
Array may refer to a plurality of individual unit cells. The
plurality of cells may be formed on a sheet of ion exchange
membrane material, a substrate, or may be formed by assembling a
number of components in a particular manner.
Unit cells according to the invention may be used in a planar
electrochemical cell 10 layer that is conformable to other
geometries, as described in application Ser. No. 11/185,755, filed
on 21 Jul. 2004, entitled "DEVICES POWERED BY CONFORMABLE FUEL
CELLS," which issued as U.S. Pat. No. 7,474,075 and application
Ser. No. 60/975,132, filed 25 Sep. 2007, entitled "FLEXIBLE FUEL
CELL," which are hereby incorporated by reference.
Arrays can be formed to any suitable geometry. Examples of planar
arrays of fuel cells are described in co-owned U.S. application
Ser. No. 11/047,560 filed on 2 Feb. 2005 entitled "ELECTROCHEMICAL
CELLS HAVING CURRENT CARRYING STRUCTURES UNDERLYING ELECTROCHEMICAL
REACTION LAYERS", which issued as U.S. Pat. No. 7,632,587, the
disclosure of which is herein incorporated by reference. Fuel cells
in an array can also follow other planar surfaces, such as tubes as
found in cylindrical fuel cells. Alternately or in addition, the
array can include flexible materials that can be conformed to other
geometries.
Referring to FIG. 1A, an example of an electrochemical cell system,
such as a electrochemical cell system 100 is shown. Although the
term electrochemical cell system is used herein, it should be noted
that the system can be used for any electrochemical cell system.
The electrochemical cell system 100, which may be characterized as
a fuel cell assembly, includes one or more of a fuel cell 102, a
fuel cell fuel system 104, a charge port 106, and fuel storage 108.
The fuel cell fuel system 104 includes a layered structure
including, but not limited to, at least one pressure regulator, at
least one check valve, at least one flow valve. In an option, the
at least one pressure regulator, the at least one check valve, at
least one flow valve include featured layers that are stacked
together and operatively interact together, for example as
discussed in co-pending U.S. application Ser. No. 12/053,374, filed
on Mar. 21, 2008 entitled "FLUIDIC CONTROL SYSTEM AND METHOD OF
MANUFACTURE", which issued as U.S. Pat. No. 8,679,694 and is
incorporated herein by reference in its entirety. The
electrochemical cell system 100 further includes a manifold 118,
such as a fuel manifold 120 fluidly coupled with a fluid enclosure
114, such as the fuel storage 108. The manifold 118 is also fluidly
coupled with the fuel cell 102. The fluid coupling for the fuel
manifold and the fuel storage can include, but is not limited to
compression seals, adhesive bonds, or solder connections.
Although a fuel manifold is discussed as an example, the manifold
can also be used to distribute, deliver, or remove other types of
fluids, such as, but not limited to water, oxidant, or a cooling
fluid.
Devices for detachably coupling the fluid coupling, such as a
pressure activated valve, can be used. For example, pressure
activated one-way valve allows a flow of fluid, for example, fluid
fuel, into a fluid enclosure for a fuel storage system. The flow of
fuel is allowed into a fluid reservoir during refueling, but does
not allow fuel to flow back out of the fuel reservoir. In an
option, flow of fuel is permitted to flow back out of the fluid
reservoir if the fluid reservoir is over pressurized with fuel.
An external refueling device can form a seal against a portion of
the sealing surface, for example, around the inlet port with a
seal, such as an o-ring or gasket. Fuel is introduced into the
fluid control system, and the fluidic pressure of the fuel
compresses the compressible member and breaks the seal between the
compressible member and the outside cover. In another option, an
environment surrounding the exterior of the outside cover may be
pressurized with fuel to force fuel through the refueling valve
assembly and into the fuel reservoir.
When the fueling process is complete, the refueling fixture is
removed from the valve assembly, and the valve becomes closed. For
example, the compressible member decompresses, and fluidic pressure
from the fuel reservoir through the fuel outlet port exerts
pressure on to the compressible member and presses the compressible
member against the outside cover. The decompression of the
compressible member and/or the fluid pressure from the reservoir
creates a seal between the compressible member and the outside
cover such that fuel does not flow past the compressible member and
into the fuel inlet port. In another option, the compressible
member and/or the fluid diffusion member can be designed to
intentionally fail if the pressure in the fuel reservoir becomes
too great, or greater than a predetermine amount. Additional
examples and details of valves can be found in commonly owned
co-pending patent application entitled REFUELING VALVE FOR A FUEL
STORAGE SYSTEM AND METHOD THEREFOR, filed on 20 Jan. 9, 2007,
having Ser. No. 11/621,542, which issued as U.S. Pat. No. 7,938,144
and which is incorporated by reference in its entirety.
In another option, a fluid coupling assembly can be used to couple
the system with another component. The coupling assembly includes a
first coupling member, a second coupling member, and a seal member
therebetween. The first coupling and the second coupling member are
magnetically engagable, such as by way of a first magnetic member
and a second magnetic member having attracted polarities. The
engagement of the first coupling member and the second coupling
member opens a fluid flow path therebetween. When the coupling
members are disengaged, this fluid flow path is sealed. Additional
examples and details can be found in commonly owned copending
entitled MAGNETIC FLUID COUPLING ASSEMBLIES AND METHODS, filed Nov.
7, 2007, having Ser. No. 11/936,662, which issued as U.S. Pat. No.
7,891,637 and which is incorporated herein by reference in its
entirety.
In a further option, the system includes a strain absorbing
interface 404 for contacting the fluid enclosure. For instance, the
interface is used for a rigid or semi-rigid component and a
flexible fluid enclosure. The interface absorbs any strain due to
dimensional changes in the fluid enclosure as it charges with
hydrogen. Rigid components, such as mounts or fluidic devices for
fuel cell communication, can be coupled to the fluid enclosure
through the flexible interface and not risk sheering due to
mechanical stress. The flexible interface allows for more component
configurations and applications for use with a flexible fluid
enclosure. The flexible interface absorbs strain and supports the
connection between component and enclosure. Additional examples and
details can be found in commonly owned co-pending patent
application entitled INTERFACE FOR FLEXIBLE FLUID ENCLOSURES, filed
on Mar. 21, 2008, having U.S. application Ser. No. 12/052,829,
which issued as U.S. Pat. No. 7,926,650 is incorporated herein by
reference in its entirety.
Referring to FIG. 6, a cross-sectional view of a flexible fluid
enclosure interface system 400 is shown, according to some
embodiments. The system 400 includes a flexible fluid enclosure 406
in contact with a strain absorbing interface 404 on a first side.
On a second side, the interface 404 may be in contact with a
featured layer 402. The featured layer may include a plurality of
featured layers, or one or more featured layers that collectively
form a functional control system component. An optional fluidic
connection 408 may be positioned in the strain absorbing interface
404, connecting the enclosure 406 and featured layer 402.
The fluid enclosure may be flexible. For example, a flexible fluid
enclosure may include a flexible liner for storing a fluid. The
fluid enclosure can include fuel cartridges, such as replaceable
fuel cartridges, dispenser cartridges, disposable fuel ampoules,
refillable fuel tanks or fuel cell cartridges, for example. The
fuel cartridge may include a flexible liner that is connectable to
a fuel cell or fuel cell layer. The fuel cartridge may also include
a connecting valve for connecting the cartridge to a fuel cell,
fuel cell layer or refilling device. The fluid enclosure 406 may be
an enclosure formed by conformably coupling an outer wall to a
composite hydrogen storage material, for example.
Conformably coupled refers to forming a bond that is substantially
uniform between two components and are attached in such as way as
to chemically or physically bind in a corresponding shape or form.
A structural filler or composite hydrogen storage material may be
conformably coupled to an outer enclosure wall, for example, in
which the outer enclosure wall chemically or physically binds to
the structural filler or composite hydrogen storage material and
takes its shape. The outer enclosure wall is the outermost layer
within a fluid enclosure that serves to at least partially slow the
diffusion of a fluid from the enclosure. The outer enclosure wall
may include multiple layers of the same or differing materials. The
outer enclosure wall may include a polymer or a metal, for example.
The fluid may be hydrogen, for example. Examples of such enclosures
may be found in commonly owned U.S. patent application Ser. No.
11/473,591, entitled "FLUID ENCLOSURE AND METHODS RELATED THERETO,"
filed Jun. 23, 2006 and issued as U.S. Pat. No. 7,563,305.
The strain absorbing interface 404 may be manufactured of any
suitable material that allows it to be flexible, absorb strain and
bond to the enclosure 406 and featured layer 402. The material
chosen should provide a suitable bond, physical or chemical,
between the featured layer 402 and enclosure 406 and also allow for
the differential in strain between the strain of the enclosure wall
and the rigidity of the featured layer 402, so that the sheer
stress on any bonds does not exceed the strength of such bonds. The
strain absorbing interface 404 may be manufactured of an
elastomeric material or silicon material, for example. Elastomeric
materials may include thermoplastic elastomers, polyurethane
thermoplastic elastomers, polyamides, melt processable rubber,
thermoplastic vulcanizate, synthetic rubber and natural rubber, for
example. Examples of synthetic rubber materials may include nitrile
rubber, fluoroelastomers such as Viton.RTM. rubber (available from
E.I. DuPont de Nemours, a Delaware corporation), ethylene propylene
diene monomer rubber (EPDM rubber), styrene butadiene rubber (SBR),
and Fluorocarbon rubber (FKM).
As the fluid enclosure 406 is filled with fluid, or charged, the
dimensions of the enclosure 406 increase (see FIG. 7). The strain
absorbing interface 404 may deform or change in dimension, such as
in thickness 412, as it is strained (see FIG. 7). The strained
interface 404 then maintains a consistent, less stressful contact
between the enclosure 406 and featured layer 402. The featured
layer 402 would then undergo little to no strain, as the strained
interface 404 absorbs strain caused by the enclosure 406 movements.
The strained interface 404 may absorb all or at least part of the
strain caused by changes in dimension of enclosure 406. The strain
absorbing interface or the strained interface 404 may be generally
characterized as interface elements.
The featured layer 402 may be any fitting, mount, connector, valve,
regulator, pressure relief device, planar microfluidic device, a
plate, or any device that might control the flow of a fluid from
the fluid enclosure into or out of the enclosure or combinations
thereof, for example. Examples of fluids include, but are not
limited to, gas, liquefied gas, liquid or liquid under pressure.
Examples of fluids may include fluid reactants, fuels, oxidants,
and heat transfer fluids. Fluid fuels used in fuel cells may
include hydrogen gas or liquid and hydrogen carriers in any
suitable fluid form. Multiple strain absorbing interfaces 404 and
multiple featured layers 402 may be utilized in conjunction with
one or more fluid enclosures 406, where the featured layers form
functional components such as, but not limited to, the fluidic
control system, the manifold, the pressure regulator, the check
valve. In another option, the interfaces 404 can be coupled with an
inlet of the fluidic control system, the fuel cell, or the fluidic
enclosure.
FIG. 1B illustrates additional examples for the manifold 118. A
fuel cell assembly 100 includes a fluid enclosure 114 fluidly
coupled with a fluidic controller, such as a pressure regulator
component 116 by a manifold 118. The one or more fluid control
components can include, but are not limited to a fluidic control
system, inlets, outlets, a check valve component, a flow valve
component, a charge valve component, a pressure relief component, a
conduit, an on/off valve, a manual on/off valve, or a thermal
relief component.
The pressure regulator 116 is fluidly coupled with a fuel cell 102
via a manifold 118. The manifold 118 includes one or more conduit
channels 130 therein, such as may provide a single ingress and
multiple egresses as shown in FIG. 1B. In a further option, the
manifold 118 fluidly coupled with the pressure regulator component
116 and the fuel cell 102 can further include at least one feedback
channel or conduit 129 and a delivery channel 133. The delivery
channel 133 delivers fluid such as a fuel to the fuel cell 102.
The feedback channel 129 allows for the regulator to be piloted
based on the feedback to the pressure regulator component 116 from
pressure in the fuel plenum, and is fluidly coupled to a fluid
plenum of the electrochemical cell system. Additional examples and
details can be found in commonly owned co-pending U.S. patent
application Ser. No. 12/053,408, entitled "FLUIDIC DISTRIBUTION
SYSTEM AND RELATED METHODS," filed on Mar. 21, 2008, and issued as
U.S. Pat. No. 8,133,629, which is incorporated by reference in its
entirety.
Each of the components of the electrochemical cell system 100 can
be formed by the flexible layered structured as discussed above and
below. In a further option, the one or more conduit channels 130
include a gas conduit channel. Multiple ports, channels, including
conduit channels or delivery channels are possible, such as shown
in FIGS. 5 and 6.
Referring to FIG. 2, the manifold 118, such as the fuel manifold
120, includes a layered structure fanned of multiple, thin,
flexible featured layers. The layered structure is made small,
nano-fabrication technologies, and/or micro fabrication
technologies can be employed to produce and assemble the layers.
For instance, processes for producing and/or assembling the layers
include, but are not limited to, microfluid application processes,
or chemical vapor deposition for forming a mask, and followed by a
process such as etching. In addition, materials for use in
fabricating the thin layered structure includes, but is not limited
to, silicon, polydimethylsiloxiane, parylene, or combinations
thereof. The manifold 120, as evident from FIG. 1A, includes a
first manifold coupled to the fuel cell 102, and a second manifold
connecting the first manifold to an outlet 206 that is fluidly
connected to the fluid enclosure 114. Port 204 connects the first
manifold to the outlet 202 of the second manifold.
The featured layers include one or more features. In an option, the
featured layers of the layered structure provides a gas-tight seal
such that the featured layers are gas-tight. For example, a bond is
provided with the layers that is impermeable to a fluid. In another
example, the bond may be substantially impermeable to hydrogen or
any other fluid at or below 350 psi or 2.5 MPa. Examples of fluids
include, but are not limited to, hydrogen, methanol, formic acid,
butane, borohydrides, water, air, or combinations thereof. In
another option, the bond is substantially impermeable to fluid at
or below 150 psi or 1.03 MPa. In yet another option, the bond is
substantially impermeable to fluid at or below 15-30 psi or
0.10-0.21 MPa. The layered structure allows for the manifold to be
of a size that does not take up unnecessary volume, nor an
unnecessarily large footprint, yet allows for the pressure, volume,
and temperature requirements for fuel cell fuel supply systems to
be met. The multiple layers can be coupled together by thermal
bonding, adhesives, soldering, ultrasonic welding, etc.
The manifold 118 can be made of relatively thin layers of material,
allowing for the manifold 118 to be flexible. In an option, the
manifold 118, and/or the featured layers that make up the manifold
118, such as, but not limited to the conduit layer 122 and/or 15
the barrier layer, are flexible enough to have a bend radius of
about 1-5 mm. In a further option, the manifold 118, and/or the
featured layers, and/or the conduit layer 122, and/or the barrier
layer have a bend radius of no less than about twice a thickness of
a single featured layer, where the thickness is optionally less
than 1 mm to 200 microns. The flexible manifold can be bent around
components, or wrapped around components, providing greater number
of assembly options for the electrochemical cell system.
The manifold 118, for fluid, includes at least one featured layer,
such as a conduit layer 122 defined in part by a first side 124 and
a second side 126. In an option, the at least one conduit layer 122
is relatively thin, for example, compared with the length and
width. In an example, the thickness of the at least one conduit
layer 122 is generally less than about 1 mm. In another example,
the thickness of the at least one conduit layer 122 is about 5
.mu.m-1 mm. In an example, the width and length of the conduit
layer 122 is about 1 mm and 100 mm, respectively. In another
example, the thickness of the at least one conduit layer 122 is
about 100 .mu.m, and the width and length of the conduit layer 122
is about 1 mm and 1.5 mm, respectively. The width and/or the length
can be altered for geometry of the system in which the manifold 118
is installed.
In a further option, the thickness of the layer is about 10-500
micron, and a dimension of the conduit channel, such as a height or
a width or a channel depth, is about 50 micron to 1 mm. The layer
is highly planar such that a width of the manifold is greater than
about thirty times the dimension of the conduit channel. In another
option, the width of the planar portion of the manifold is greater
than three times the dimension of the conduit channel.
The at least one conduit layer 122 includes at least one conduit
channel 130 therein. In an option, the conduit layer 122 includes a
plurality of conduit channels 130 in the conduit layer 122, and in
a further option, in each of the conduit layers 122. The plurality
of conduit channels 130 are disposed adjacent one another in a
single layer. The at least one conduit channel 130 can also be a
recess or a partial recess or channel, and is a conduit channel
that allows for material such as a fluid to flows therethrough. The
at least one conduit channel 130, in an option, extends through the
conduit layer 122, from the first side 124 to the second side 126,
as shown in FIG. 2 and FIG. 3A. In another option, the at least one
conduit channel 130 extends only partially within a side of the
conduit layer 122, as shown in FIG. 3B. In yet another option, the
conduit layer 122 includes two or more conduit channels 130, within
a single conduit layer. For example, two or more conduit channels
130 which extend from the first side 124 to the second side 126 can
be disposed within the conduit layer 122, as shown in FIG. 4. The
two or more conduit channels 130 can include recesses that extend
partially within a side of the conduit layer 122 (FIG. 3B) and/or
the conduit channels 130 can extend through the conduit layer 122
(i.e. from the first side 124 and through the second side 126). The
conduit channels 130 that extend partially within the featured
layer, optionally can be fluidly coupled with one another.
The two or more conduit channels 130 can be formed within the
featured layer such as the conduit layer 122 such that they do not
intersect with one another in the conduit layer 122. Alternatively,
the two of more conduit channels 130 can be formed within featured
layer such as the conduit layer 122 such that they do intersect
with one another or are fluidly coupled in the conduit layer 122.
The conduit channel 130 extends along the conduit layer 122, and
allows for material such as fluid or fuel to flow therethrough. In
an option, the conduit channels 130 and/or ports are sized and
positioned so that flow therethrough is non-restrictive, which can
be combined with any of the embodiments discussed above or below.
For example, the conduit channels 130 and/or ports are sized
similarly throughout the manifold so that flow therethrough is not
restricted by changing the cross-sectional size of the channels or
ports. In a further option, the conduit channels are delivery
channels, where the channels deliver fluid such as a fuel. In a
further option, the conduit channels include a feedback channel,
for example for varying actuation of a regulator based on the
pressure in a fuel cell fuel plenum. In yet another option, the
conduit channel is a gas conduit channel.
In a further option, the conduit channel includes a channel having
a surface allowing for non-restrictive flow. For example, the
conduit channel has a surface roughness that is 1/50.sup.th of the
hydraulic diameter of the channel. In a further option, the fluid
for the conduit channel includes a gas, such as a low viscosity
fluid that reduces inhibitive capabilities of the channels,
including, but not limited to, hydrogen.
In another option, a conduit channel such as a first recess 132 can
be formed on the first side 124 of the conduit layer 122, and a
second recess 134 can be formed on the second side 126 of the
conduit layer 122, where the first recess 132 and the second recess
134 do not necessarily extend from the first side 124 through to
the second side 126. In an example shown in FIG. 3C, the partial
conduit channels or recesses 136 are disposed on opposite sides of
the conduit layer 122, allowing for material to travel therethrough
via the recesses on the first side 124 and the second side 126.
The conduit layer 122, in another option, is formed of metals,
plastics, elastomers, or composites, or a combination thereof. The
at least one conduit channel 130 is formed within and/or through
the conduit layer 122, in an option. For example, the at least one
conduit channel 130 can be etched or stamped on, within and/or
through the conduit layer 122. In another option, the at least one
conduit channel 130 can be drilled within and/or through the layer,
formed with a laser, molded in the layer 122, die cutting the
conduit layer 122, or machined within and/or through the conduit
layer 122. In an option, the at least one conduit channel 130 has a
width of about 5 to 50 times the depth of the recess. In another
option, the at least one conduit channel 130 has a width of about 1
mm-2 mm. In yet another option, the at least one recess has a width
of about 50-100 .mu.m.
One of the featured layers of the manifold 118 further optionally
includes at least one barrier layer 140, as shown in FIG. 2. The
barrier layer defines a portion of the conduit channels 130, for
instance a wall portion of the conduit channel 130. In a further
option, the manifold 118 includes a first barrier layer 142 (which
may be characterized as an upper barrier layer) and a second
barrier layer 144 (which may be characterized as a lower barrier
layer) disposed on opposite sides of the conduit layer 122. For
example, the first barrier layer 142 abuts and seals against the
first side 124 of the conduit layer 122, and the second barrier
layer 144 abuts and seals against the second side 126 of the
conduit layer 122.
This allows for the conduit channel 130 to be enclosed and form a
conduit through which material travels. The barrier layers 142, 144
can be coupled with the conduit layer 122, for example, but not
limited to, using adhesives, bonding techniques, or laser welding.
In a further option, the barrier layers 142, 144 and a featured
layer such as the conduit layer 122 are stacked together, and
further optionally sealed together. For example, the layers 122,
142, 144 are stacked and optionally coupled together through
thermal bonding, adhesive bonding, gluing, soldering, ultrasonic
welding, diffusion bonding, heat sealing, etc. In a further option,
layers 122, 142, 144 are joined by gluing with cyanoacrylate
adhesive. In yet another option, layers 122, 142, 144 could be
built up and selectively etched as is done for MEMS and/or
integrated circuits.
The layers 122, 142, 144, in an option, include one or more bonding
regions 369 allowing for flowing adhesives or other bonding agents
so that layers can be bonded without the functional components, the
conduit channels, or ports also being bonded. In a further option,
the one or more featured layers include barrier features, such as,
but not limited to, physical barriers such as ridges, or recesses
and/or chemical barriers that separate bonding regions from
functional regions and/or prevent bonding material from entering
function regions.
In a further option, the featured layers can form one or more of
the barrier layers 142, 144 including one or more ports or holes
150 therein. For example, the one or more ports 150 or a first and
a second hold to form an inlet 152 and an outlet 154. The inlet and
outlet 152, 154 are positioned within the second barrier layer 144
such that they are fluidly coupled with the conduit channel 130.
For example, the inlet and/or outlet 152, 154 are positioned
adjacent to at least one conduit channel of another featured layer,
for example as shown in FIGS. 2 and 4. Material such as fluid fuel
can travel in through the inlet 152, through the conduit channel
130, and out of the outlet 154. The one or more ports 150 provide
fluid communication between the manifold 118 and components to
which the fuel manifold 120 is coupled, such as, but not limited
to, a fluid enclosure such as the fuel storage 108 (FIG. 1A) or the
fuel cell 102 (FIG. 1A or 1B). The one or more ports 150 can
further provide fluid communication within the manifold 118, for
example, between various featured layers. It should be noted that
it is possible to use the manifold 118 as a fluid distribution
system where there is a single inlet 200 and multiple outlets 202
so that the manifold 118 feeds multiple locations, for example on a
fuel cell layer. FIG. 1A shows a manifold 118 with inlet 200 formed
by a hole on a barrier layer and an outlet 202 formed by another
hold on another barrier layer. Inlet 200 is fluidly connected to
outlet 206 of fluid enclosure 108, 114, and outlet 202 is fluidly
connected to port 204. The fluids usable with the manifold 118
include, but are not limited to: fuel, water, coolant, or oxidant.
Examples of fluids which may be used could include, but are not
limited to: hydrogen, methanol, ethanol, butane, formic acid,
borohydride compounds, such as sodium and potassium borohydride,
and aqueous solutions thereof, ammonia, hydrazine, silanes, or
combinations thereof.
In a further option, a filter element 131 can be incorporated into
a part of the flow path. For example, the filter element 131 can be
disposed within the conduit channel 130, as shown in FIG. 3A. In
another option, the filter element 131 can be disposed within the
ports 150, such as the inlet 152. The filter element 131 can
include a porous substrate or a flow constricting element. In
another option, the filter element 131 can define the conduit
channel 130. The filter element 131 disposed within the conduit
channel 130 and/or the ports 150 assists in preventing collapsing
of the conduit channel 130 and/or port 150 for instance, when the
fuel manifold 120 is bent around itself or other components within
the fuel cell assembly. In a further option, the conduit channel
130 extends along the conduit layer 122, and the conduit channel
130 is defined by a length.
The filter element 131, in an option, extends along a portion, or
the entire length of the conduit channel 130. In an option, the
filter element 131 is a porous substrate.
FIGS. 4 and 5 illustrate additional options for the manifold 118,
where the fluid manifold includes multiple featured layers.
Referring to FIG. 4, the fuel manifold 120 includes the at least
one conduit layer 122, a first barrier layer 142, and a second
barrier layer 144. The first barrier layer 142 and the second
barrier layer 144 include one or more ports 150 therein. The at
least one conduit layer 122 includes conduit channels such as a
first recess 132, a second recess 134, and a third recess 136. The
first, second, and third recesses 132, 134, 136 extend in a pattern
within the conduit layer 122, and line up with their respective
ports when the layers are stacked together, such that there is
fluid communication. The barrier layers 142, 144 can be coupled
with the conduit layer 122 using, for example, but not limited to,
adhesives, bonding techniques, or laser welding.
In a further option, the barrier layers 142, 144 and the conduit
layer 122 are sealed together.
FIG. 5 illustrates another example of a manifold 118, which also
includes multiple featured layers. For instance, the manifold 118
includes multiple featured layers including at least two conduit
layers 122, a first barrier layer 142, a second barrier layer 144,
and a third barrier layer 146. The conduit layers 122 for the
various embodiments herein can serve as a barrier layer and conduit
layer, and various features such as ports or conduit channels, or
partially recessed channels can be formed in one or more of the
featured layers, alone or in combination. The layers include at
least one conduit channel.
The conduit channel includes, but is not limited to a delivery
channel, or a feedback channel.
A first conduit layer is disposed between the first barrier layer
142 and the second barrier layer, and a second conduit layer is
disposed between the second barrier layer 144 and the third barrier
layer 146. It should be noted that additional layers, including
conduit layers and barrier layers could be incorporated into the
manifold 118 for additional material flow options.
The first barrier layer 142 and/or the second barrier layer 144
include one or more ports 150 therein. It is possible for the third
barrier layer 146 to further include one or more ports 150 therein.
The ports 150 allow for material to flow in to and out of the fuel
manifold 120, and further to flow between the multiple conduit
layers 122. The at least one conduit layer 122 includes one or more
recesses therein 130. The multiple recesses 132, 134, 136
therein.
The barrier layers 142, 144, 146 can be coupled with the conduit
layers 122, for example, but not limited to, adhesives, bonding
techniques, or laser welding. In a further option, the barrier
layers 142, 144, 146 and the conduit layers 122 are sealed
together. The various layers, including the featured layers and/or
the barrier layers and/or the conduit layers allow for a flow path.
In an option, a first flow path allows for fluid, such as gas, to
be distributed on two more layers, where the first flow path
extends from a first featured layer to a second featured layer. In
yet another option, the flow path returns from the second featured
layer to the first featured layer. In still another option, the
first flow path circumnavigates a second flow path.
The fluid manifold provides a layered structure allowing for fuel
distribution in a relatively small amount of space. For example,
the fuel system can be made with an overall thickness of about
50-100 .mu.m, or in another example the overall thickness is about
20-100 .mu.m The fuel cell fuel manifold further allows for the
transport of fuel, such as gas, while maintaining certain levels of
pressure. For instance, hydrogen gas can be distributed through the
layered structure of the fuel manifold while pressure in the range
of 2-10 psig.
The fluid manifold interacts with or can be coupled to the fuel
cell or other system components using adhesives working over
comparatively large surface areas to that the force due to internal
fluidic pressures that is forcing the components apart is easily
overcome by the strength of the adhesive bond. A high internal
pressure can be counteracted with a bond that has a relatively low
tensile strength.
FIG. 8 illustrates an exploded view of an electrochemical cell
system, as constructed in accordance with at least one embodiment.
The fuel cell system 800 includes, but is not limited to, one or
more of a fuel cell layer 802, fluidic controllers 804, a charge
port or inlet 806, a fluid reservoir 808, or a current collecting
circuit 810. In one example, the fluid reservoir 808 is filled with
fuel by pressurizing the charge port or inlet 806. In another
example, power from the fuel cell layer 802 is utilized by the
current collecting circuit 810, which collects the power from the
fuel cell layer 802 and routes it out of the fuel cell system
800.
A method includes introducing fluid, such as a fuel, into a fluid
manifold, the manifold including two or more featured layers each
having a plurality of conduit channels. In an example, the fuel
includes a gas or a liquid such as, but not limited to, hydrogen,
hydrogen, methanol, ammonia, silanes, formic acid butane, or
borohydrides.
The method further includes flowing fluid through the conduit
channels. The conduit channels include, but are not limited to,
fuel channels, feedback channels, or delivery channels.
Several options for the method are as follows. For instance, the
method optionally includes providing fuel to a fuel cell assembly,
where the fluid manifold is fluidly coupled with the fuel cell. The
method optionally includes flowing material from a first layer
recess of a first conduit layer to a second layer recess of a
second conduit layer, and/or flowing material through a porous
substrate within at least one of the one or more conduit channels,
and/or providing a heat transfer fluid to a electrochemical cell
system through the conduit channels. The method further optionally
includes providing oxidant to a electrochemical cell system through
the conduit channels or removing water from the electrochemical
cell system through the conduit channels.
Further options for the method are as follows. For instance,
flowing fluid through one or more conduit channels includes flowing
fluid along a partially recessed channel in the conduit layer,
and/or flowing fluid through one or more conduit channels includes
directing material along a first partial channel in the first side
and along a second partial channel in the second side. In another
option, the method further includes coupling with a charge port,
and/or coupling with fuel storage. In still another option, the
method further includes distributing fluid on two or more layers
via at least a first flow path, the first flow path extending from
a first featured layer to a second featured layer, and returning
from the second featured layer to the first featured layer.
In the description of some embodiments of the invention, reference
has been 20 made to the accompanying drawings that form a part
hereof, and in which are shown, by way of illustration, specific
embodiments of the invention that may be practiced. In the
drawings, like numerals describe substantially similar components
throughout the several views. These embodiments are described in
sufficient detail to enable those skilled in the art to practice
the invention. Other embodiments may be utilized and structural,
logical, and electrical changes may be made without departing from
the scope of the invention.
The following detailed description is not to be taken in a limiting
sense, and the scope of the invention is defined only by the
appended claims, along with the full scope of equivalents to which
such claims are entitled.
* * * * *